Machining a Custom Mounting Bracket
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- čas přidán 13. 09. 2024
- The local Air Power Services was in need of a custom aluminum bracket machined to be used on a new compressor equipment install and they needed it done quickly. No one else in town was willing get on it right away, so I did and had fun machining it too. I used Fusion for the simple CAD program and my @MilltronicsUSAInc TRM3016 toolroom mill to knock out the machining. The cnc sure made simple and fast work of that large radius.
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It must be a great feeling to finally, after all this time of building and learning, and all the doubters, to have a job that could show how CNC can be valuable even to a small job shop without it needing to be for a large batch, and know you have the skills to knock it out quickly. Cool journey, Adam.
I will admit, the cnc stuff is growing on me. But, I would LOVE to see this particular operation done manually. Mainly because I can’t afford a 100k machine
Sweet. I have a $30k machine in my garage that could do the same part. There are CNC machines available that are $15k that could do that same job. So these machines aren't quite as unaffordable as you may first think.
@@RedBear345 You can just join the club :) I work with a lot of people that discover that really good CNC equipment can be had for a lot less than they imagined. In the last 10 years, there CNC software and machines have more affordable options for the people interested.
One way to do a radius like this on a manual mill is also to mount the part on a rotary table and cut it with the side of an end mill. It takes a while to set up but works pretty well once you’re there. Probably faster than freehand roughing it then setting up a boring head 😊
@@ramanshah7627 This is about a 6" radius curve needing a 15" RT, what do you do when it is a 12" radius curve? CNC will do both and more. Learn how to do it once with CNC and then you know that you can do any other radius.
@@martinconnelly1473 No harm no foul, you're right, and it's good logic. Cutting a radius where the radius approaches infinity is a killer app for a CNC mill. I was just responding to the initial commenter. I learned/did all my machining during my Ph.D. to make components for our physics experiments, and we only had access to manual machines. That's when I did the rotary table setup I discussed (to make a brass counterweight that mounted flush to the outside of a big tube). Now I'm just a civilian and don't have anything more impressive than a drill press in my basement. I'd happily learn CNC, but there's nearly zero chance I'll ever have the chance to operate a CNC machine. But I'm still eager to do good things with what I do have.
OK I gave everyone a thumbs up👍🏽 I do miss the old a bomb, bare knuckle, fighting material, flipping levers ,turning handles 😂😂 the new shop is definitely out of this world a dream shop for anyone even me❤
It's great you're getting comfortable with CNC. Nice video, as always.
I'm proud of you describing a manual process to cut this and then switch around and say "I'm going to use the Milltronics" which means that you are getting more comfortable with CNC and really taking an effort to learn new things.
You are building your confidence with your programming skills and it shows with a big smile on your face.
I enjoyed watching the show.
Good to see Kevin rubbing off on you! He's changed my machining completely! Good work Adam thanks for sharing it!
You are changing your own path. I just get to help a little :)
Adam,
Would you consider doing a comparison video of you doing the same job using manual machines only? Not to prove anything - just to satisfy a curiosity….
It would be very interesting to see the time difference between CNC, and manual machines - same Machinist, different machines.
❤ all the content you produce, and I am happy that you are successful and enjoying your new shop!
Dude, I'm 3mins 58 seconds in and already super impressed on how this video looks, and how your talking about what your doing with some gusto. Good for you buddy keep learning it's making great videos.
The smile tells me you are enjoying this. Thanks for sharing.
Adam, great job and keep it going! The mixed machining content is great!
(In my opinion).
Like to hear you going through the CMM thought processes, errors and all. Its real!!!!
Adam, this video made me very happy for you. It’s been a long road, but seeing your confidence and success with this little job is heartwarming. Thank You for being so honest in showing your work and what it’s taking for a highly skilled manual machinist to leap forward with both feet. Kudos.
Great to have another midweek episode from you Adam keep them coming!
Nice work! Your confidence is growing and you are doing great.
awesome to see your confidence build on the cnc side, glad you are enjoying it now.. as always right tool for the right job.
Adam great video, i especially love how you are embracing change being an old school machinist it is awesome to watch and learn along with you.
LOL, I feel like a barbarian, as I thought, and probably would have, cut that curve on the bandsaw, with a bit of filing, followed by a visit to the polisher!
I guess I'm a barbarian too!
I always enjoy the small jobs. We get to see the whole process and you explaining along the way. Great video as always Adam!
2 minutes on a bandsaw!😂
Follow up on the belt grinder. Most folks don’t have a CNC Mill…
@@gus9675 Yeah, you really have to get creative at times don't ya. Lol
I like your use of the word 'elegant'. It seems that way to me, and in a general way I think going for the elegant solution elevates the level of anyone's work.
I’m enjoying this series of running one off parts with the CNC, demonstrating that it is economical.
Adam - Nice job. Nice to see you not hesitating to *add* CNC to your repertoire of skills. If you were at the home shop I could just as easily have seen you run that web-reduce side on the shaper... just because it would be fun to do. Adam likes big chips! ;)
Need one of those air powered spinna-ma-thingies that AvE has to have a clear spot for viewing that whirls the coolant off.
New music Outstanding !!!
Nicely done thanks for sharing
Excellent! Next time they need one of these you can knock it out in 10 -15 minutes while they wait as the program is already written.
I'm seeing a few critical comments. I think Adam probably could have knocked this out in 5 minutes on a manual mill but wants to use this as a chance to improve his skills with the CNC. If he always goes with what's comfortable, he'll never learn.
Perhaps he should still use traditional machining techniques, even on a CNC for an economical job time.
I don't disagree but you're missing my point. One day a customer will want 200 of those brackets and now instead of feeling anxious about not doing it before, he'll jump right into it and possibly differently because he's learning a lot.
He now has information about how long programming and setup takes and can factor that into a decision to do it old school or cnc. This was an investment into himself
@@Tezza120 if he gets an order for 200 then he will definitely want to revisit the orientation he uses. Ignoring the traditional proven methods will bite him 200 times.
It's so good watching you learn these new machines. Thanks for sharing it with us.
Look into prototraks their conversational programming is really nice. All the benifits of a manual, with quick cnc programming. The 3d surfacing gets a little more complicated with conversational tho
I'd use a bandsaw (or a hacksaw) and a file.
I just cut it with a jigsaw, then sand it smoothe with a grinder or belt sander. ( Have done it before). Then drill any holes needed!
Good rescue project,Adam.Thank you.
Use your ball mill to put chamfer on for perfect blend in
The machine sure was singing a pretty song when it first started cutting the radius....
Hacksaw and file 15 min job!
But ... I thought according to the haters you have no customers! What do you mean you just did a rush job for air power!
Another awesome video ABom!
Adam, have you considered applying something similar to RainEx to the inside of the glass doors and mount a air hose nozzle to blow air across the glass on the inside to clear the water droplets. This way you wouldn't ever have to put cameras inside the machine.
This is what clear view screens are for (ave fitted one to his cnc a while back, they also use them on ships), you don't want to mix other chemicals into your coolant i don't think.
Edge precision made a nice camera case w/air ports that blasts the overspray before it hits the camera
If I had to make that part manually ...it would be done on the band saw and bench grinder. Which is not to say thats the right way to do it, but thats how I would end up doing it.
Not a bench grinder but an oscillating spindle sander with a coarse grit sleeve to the line. Aluminum sands like hardwood, but you would be amazed how many woodworkers do not know that and have me machine things like this for them.
@@37yearsofanythingisenough39 Love my Triton POS spindle sander for Timber and Ali 👍My 14" Timber bandsaw also does great on Aluminium. For Long Straight Cuts my Cheap Tracksaw with the 'proper blade' eats ALi Checkerplate at 2 or 3mm. Not giving up my CNC mill however 😜
Bandsaw makes quick material removal(plus the cutoff could possibly be saved for customer to use if desired instead of turned to chips). Same with cutoff on straight side.
Good for you. I didn't think you were gonna CNC that for a minute!
I love your content and love to learn new things like CNC usage, but I started watching your content to see your amazing manual machine skills.
With content like this it would be amazing to see you do the part first in the CNC, then in the mill, and finally the easy way in the lathe.
I feel like your Y axis was off slightly on the radius, too, and that's why you had the step. It doesn't matter for what it is, just another day learning and doing.
Another nice, relatively simple, project! I learned my drafting the old-fashioned way: Pencil on paper, then ink on vellum. Never got into CAD either. We had Intergraph at Southern Tech (SPSU) but by the time I was FINALLY graduating with my second MET degree I was so burned out after so many years (13 all told) of working full time and taking night classes I was NOT going to take one more class! I HAVE just got Fusion though and I'm looking forward to playing with it (even though I'm retired from Engineering as a job) ...
Similar experience here. Learned drafting on the board in high school and continued in college. CAD was terrible back then and I really despised it and thought it took the artistry and skill away. Now that I have CNC milling and lathe capability in my home shop, CAD is a must-have tool. I now model in Solidworks and CAM using BobCAD. Never fear however, I still have a board in the shop, just for the simple stuff!
@@charlieromeo7663 I still have a board. Fantastic almost free one. I bought a drafting table from work many years ago for $80.00. Huge thing, flat no tilt. BUT it had a K&E drafting machine on it. I kept the machine and sold the table alone for, yep, $80.00! Later on at another job we got a bunch of office furniture and other things, among them a nice tilt table which I bought for $20.00. I put the K&E machine on IT and as I type this it's 10' away from me! 😁
You could clamp it in long length of your workpieces on vise and finsh it all in one setup with an endmill and less time
Since you asked, as a business owner I would go back to the client and see how critical that specific radius is. Ask what’s the purpose and try and get pictures from them. Someone may have just drawn that radius on there without thinking too much. I’d try and see if it could be milled normally with a large end mill. Like to mill out a pocket instead of a radius. Would make it so much easier and cheaper for the client.
As we all know, the customer is always WRONG!
The customer is the one that handed him the part with it marked up how he wanted it.
Fun little project. Always look forward to your videos.
As an aerospace guy, I would have to rough it out, have it stress relieved and then finish machine to size.
That's the problem with aerospace guy's in a job shop. You wanna make everything a watch and can't make time on jobs lol.
Pluss write a 856 page report
That's why precision costs so much. You missed out inspection and certification as well. There is an old saying, perfection is the enemy of good.
I would have had it rotated in the vice 90 to cut the profile. But I know your also practicing things with programing.
you also would've introduced another set up to chamfer the other side
@@snowdog90210 Back side chamfer.
@@soundgod06 He didn't have a backside chamfer tool and no time to order. The job came in late that afternoon, and was machined the next morning and picked up by lunch.
@@snowdog90210 The chamfer was only 0.010" which he still cut by hand to remove the burrs left by the chamfer tool.
Everyone else would use the side of a cutter holding the part at 90 degrees for both edges.
My thoughts exactly. Just clamp it on one of the sides so the other is hanging over the vise and then sidemill it. The material looks thick enough to get away with it. Afterwards you could even just flip it around and not even have to reindicate.
Not for everyone to follow the herd of sheep)
@@CatNolara Exactly. 15 mins on a prototrak, I cut per side with a fine pitch rippa. Why use the end of an endmill on Aluminum where chips can get clogged in the flutes worse still a ball nose cutter where there is hardly any chip gully at the point. No need to use any special jaws on the vise. As you say no need to indicate for the flat side. If the straight line program is longer than the part then loaded anywhere within reason will be ok.
@@Rimrock300 Yes but the customer is paying for 1.5 hours work and the part has talon grip marks on it.
Yep. 2d adaptive to rough, 2d contour to finish. 2d chamfer the top edge then use a thread mill or back deburring tool to get the bottom edge all in a single setup. This is a 20 minute job including the programming.
Interesting to see how that part was machined on the CNC. I would have sawed the radius and excess material close to the line on my bandsaw leaving a little for finishing. Probably about 30 minutes total.
In my home shop I use a hack saw for a radius cut.
That will also build your character 😂
And some mucle..
nicely done
Great job. Thank you 😊
I did enjoy watching the video! Thank you!
Great job that was fun to see you master this process
The nice thing is if you get a repeat job you can have the program saved to use again.
More and more traditional mechanics began to like CNC, and tried to use CNC to reduce the workload
Nice!
Glad to see Adam's confidence growing. Manual milling has its place but CNC milling needs to be learned for any machinist to have a future.
That is not untrue at all...as someone with zero machining experience I completely disagree with my statement.
I really want to see him set up multiple stations on that FlexCNC ..like 3 or 4 identical parts .. and just let the machine go to town
Automation does ease up things but the down side is reall hand work that shows expertise and experience. Well we have to look live with that. I still wonder that the first lathe made was all hand made.
Very nice work sir. You make it look easy
Beautiful job those fancy machines do..... lol. I wish we were buddies and I lived closer to Florida...!
I'd have probably done that radius on my lathe.
Of course, I don't have the CNC, and my mill would be too small.
I think you did it right 👍🏻
I made a fixture for my rotary table. 20" radius easy.
Cool stuff.
Smart job. Reminds me of chomping a slice of watermelon 😂
Try to get your adaptive pattern for the step cut on radius to run as an oval. Your losing time with the Z axis return between each cut. Feed rates are also low based on spindle load.
Nicely done adam.
Kimber
Another fine job Adam your the man.😊
Hi Adam, does Milltronics make a spinning glass window like on ships to be able to see the milling process?
Will he remove the marks left by the Talon jaws before they collect?
Machine a frozen ice sculpture,Frozen has a dimension reading, its better than a pumpkin, @NYC CNC
I love you channel and I really like your intro music. Can you tell me where you got it. I want to hear more of it. It’s super relaxing.
I think it's from a free for use library like the picture ones. Budget Buildz has used the same music a couple of times lately also.
table saw and a rotary table
Alumium!
Nice, I would have cut the excess off in the bandsaw, save on cutting time and also get to keep a bit of aluminium for something else
Hay Adam for your camera set up maybe try forced air on the camera lens while it is cutting to blow the cooling fluid off the lens. Give it a try and thanks for the great video
You could easily used the ball endmill to make the chamfer too.
I like it. That shows good lateral thinking combined with experience and the blindingly obvious. Great comment and tip for the viewers.👍👍👍
That was just cooler than the other side of the pillow. I enjoy the mix of new school and old school in your content. 🥸👍👋✅
What air guns do you use?
Quel momento in cui ci si rende conto che i commenti sotto un video possono essere ancora più divertenti del video stesso😻
Did you program this on the conversational control or did you program it in CAM? Would’ve been interesting to see how you programmed the first op.
He did it in Fusion CAM.
It would be nice to hear some of the feed back from your customer for projects like these.
Let me guess. How much!! 😠
Have you ever thought of getting a Spinning Viewing Port for your CNC, if you watch AvE he fitted one to his CNC and it works great, by spinning it fling the coolant away keeping your view clear for you or your camera :) love your work. Thanks
Was the role due to the softness of the material?
IMHO, one setup in a CNC, using a large diameter end mill and rough the radius and edge cut, then using a second pass finish the two cuts and chamfer.
You're learning a lot in a very short period of time. Congratulations to both you and your teacher!
Using the Renishaw probe was elegantly and efficiently done. I would suggest that you do something similar for the second setup, because the width of the chamfers is sensitive to the placement of the part.
I don't know how to do this in CNC, but basically the probe program produced a block of three numbers that represented your reference position. Any other point on your CNC system could also be represented by a block of three numbers in the same form. I suspect that you are using some special CNC memory for this. However, I expect that the CNC mill also provides some memory in which you could store a copy of this block. Again, I expect that a CNC program could be programmed to "read" a stored memory block. If so, then I think that it would be a good learning experience to write a second CNC program that reads the numbers and checks for errors. This second CNC program could produce a result code, such as zero for OK, one for "material too thick", two for "needs tramming", etc. For repetitive jobs, especially with expensive starting materials or delicate tools, this could save you a lot of aggravation.
Everything you said is where fixturing and soft jaws come in.
The machine stores the XYZ position of the setup in the control as a work offset. You can have multiple work offsets - say one for OP1 (G54) and one for OP2 (G55).
Probe your first part, and then set a vice stop for subsequent machining. This will allow placement of the next piece of stock without having to reprobe it every time.
Same thing can be done for OP2, or if part shape requires it just mill a set of soft jaws that matches the part contour and probe either a feature machined into the jaw or a thru hole in the part that you machined in OP1 if it has one.
Of course the program will need to call the correct work offset for the operation it is doing. But in general if all you're doing is setting your work offsets with the spindle probe then it is extremely underutilized precisely because the steps defined above render it unnecessary.
@@cskovach , nice comments. However, Adam often takes jobs where only a few parts are requested. In this particular case, I could see his customer wanting similar brackets, but with different cutout shapes.
At a higher level, I am aware that I come from software engineering rather than CNC machining. I have a lot of respect for machinists, and am trying not to use specialized terms like subroutines and data structures.
I have done some woodworking, where most of us try to follow the advice of "measure twice, cut once".
@@stuartschaffner9744 if you have to make similar but different parts you can either write a generic macro with input parameters to allow for some flexibility, called as a subroutine within the context of a larger program or you can just write a different program specific to that part. There isn’t really a need to make it more complicated than that.
@@cskovach , I agree. I didn't want to use software-engineering terms like module and subroutine until I heard someone from the CNC community use them.
My only quibble with what you said is that often customers for a specific part on a specific day might want similar parts on future days. In particular, a mounting plate often has some properties determined by what item is to be mounted and other properties determined by what that item is to be mounted on.
In the current example, Adam discussed how certain aspects of the adaptor plate were determined by his customer's products but other aspects were determined by what could get in the way. If the modularity of the program reflects the modularity of the customer's needs, it will be easier to modify the program the next time the customer has a rush job like this.
cool
Bolt it on the rotary table clock the radis put a ripper cutter in full depth and turn the handle
Clean the mill down and have a coffee
Have you calculated the diameter of that cut? My estimation is 12". That means in order to bolt this on, a rotary table in excess of Ø15". That is a lot of time setting up for the cut then clearing away afterwards if you even have a RT that size. They weigh about 300 pounds (135kg) and are not the sort of thing you leave on the machine in case you need it at some point. What if the next job similar to this comes in needing a 12" radius curve to suit Ø24" ducting? What use is your 15" RT then?
@@martinconnelly1473 What do you use when you don't have a cnc mill ???
Like we all did "use the rotary table"
What would Josh Topper or Keith Fenner use?
@@theessexhunter1305 Careful marking out, cut out most material with a mill then file to final size. You can't safely cut large radii on a rotary table by extending the top because you can destroy the gear teeth with the leverage of a long arm, I've seen it.
Late 70's - mid 80's while a teenager I helped out my Dad stuccoing houses when I wasn't in school. I broke my ass for just $20 bucks a day and I thought I was rolling in the money! Gotta love that cheap labor, huh?
U could use a rotary table.
That would be a pretty big table though.
very cool man....your Grandpa would be saying .... wth is going on here ... haha
I saw this same video in the past couple of weeks. Maybe on Facebook?
guess he puts out videos on FB and Instagram quite regualry, several times a week,
its a chord of a circle
Stopped at 3:40 to post. Clamp 7/8" flange in the vice, 2d contour the 18" radius as OP 1. Turn the part, buzz off the 7/8" flange as OP 2.
I guess if you're using this as a means to practice Z-contour milling for future die-type jobs, then cool. Just seemed like a lot of effort to machine it that way when there are more direct options.
He wanted to do it this way so he could chamfer both sides of the cut. Plus it was a good learning experience. And it was still pretty darn fast to do.
I wondered that too. Dang, I thought I was fancy by having a Haas TM1 in my home shop, but that probe really is just cheatin’ !
You did those 'ops' in the wrong order. Clamping across that radius is asking for more vibration, chatter.
Agreed. Or just the one op.
Couldn't you have milled that radius side-on if you'd clamped it at 90 degrees? No need for a ball mill then.
Quick question why don’t you send your g28 home z and y at end of program m30 instead of having your tool right above part and y way out there? Where you have to jog everything back up and towards you?
I have asked him that before... never got an answer unfortunately...
@@joecolanjr.8149 We would need to modify his post processor to make that happen. Without doing that, he would have to manually type in the code each time.
❤
It seems to me that a lot of the cnc milling is done "climb milling" does it no matter with these machines?
Climb milling is only a problem if the leadscrews have significant backlash, like with ACME threads. CNC machines usually use ball screws which have effectively no backlash, so you can climb mill with all the advantages and no drawbacks.